Sawhorse rail with adjustable workpiece support

ABSTRACT

A sawhorse with the horizontal rail having an inner chamber housing a plurality of linearly aligned, upwardly projecting work support elements above a laterally moveable skid. The skid has a plurality of linearly aligned upwardly projecting ramps. The ramps elevate the work support members above the rail for supporting workpieces above the rail when the skid is moved in one direction and allow the work support elements to retract into the chamber when the skid is moved in the opposite direction.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to provisional application Serial No.60/196,583, filed Apr. 13, 2000.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

BACKGROUND OF THE INVENTION

The present invention relates to an apparatus for supporting workpieceson a sawhorse, and more particularly, to an apparatus for alternativelysupporting workpieces directly atop a sawhorse beam or supportingworkpieces above the sawhorse beam on a series of adjustable pegs toprovide operational clearance for tools between the workpieces and thebeam.

“Sawhorse” is a generic name for a device that generally consists of ahorizontal beam or rail supported by two pairs of opposed legs thatdescend from the rail, generally at an angle away from each other, toprovide stability to the rail. While most sawhorses stand about 30 to 36inches tall, some collapse or fold by various means for easier storageand transportation.

Sawhorses are used by carpenters, tradesmen and others, to supportobjects, workpieces and materials, such as boards and plywood,(collectively “workpieces”) during construction-type operations. Thesetypes of operations cover a broad range of activities, includingsanding, buffing, cutting, drilling, nailing and gluing. Many of theoperations are accomplished using motorized “power” tools, such ascircular saws, jig saws and power drills. During operation, many tools,and in particular power tools, must penetrate below the bottom surfaceof the workpiece. That is, to cut a board in half, for example, aportion of the blade on a circular saw actually extends below the bottomsurface of the board. Similarly, to drill a hole through a plank, thedrill tip must fully penetrate through the bottom surface of the plank.

Such penetration can cause difficulties when, for example, the cuttingor drilling traverses the area of the workpiece that is resting directlyon the rail of the sawhorse. In order to prevent damage to theworkpiece, the sawhorse or the tools, the workpiece must be repositionedon the support surface during the operation. In fact, the workpiece mustoften be repositioned multiple times to complete a single operation. Forexample, when ripping a four foot by eight foot sheet of plywood with acircular saw, the plywood sheet may be repositioned several times toavoid cutting the rail of the sawhorse. This imparts inefficiencies inall such operations and may cause the user to take unnecessary risks tothe equipment, the sawhorse or himself in order shorten the timerequired to perform each such operation.

Accordingly, it would be desirable to have a sawhorse design that allowsoperations to be performed on a workpiece supported by the sawhorsewithout risking damage to the workpiece or the sawhorse, and withoutrequiring time consuming steps to reposition of the workpiece.

SUMMARY OF THE INVENTION

The present invention resides in a sawhorse rail design that elevatesthe supported workpiece above the surface of the rail itself, such thatoperations that would otherwise require repositioning the workpiece atopthe sawhorse to avoid encountering the rail can be performed withoutsuch repositioning. This improvement allows the carpenter or othercraftsman to utilize the sawhorse more efficiently without the concernthat an operation may unintentionally cause damage to the rail, thetools or the workpiece.

Generally stated, the invention includes a novel rail. The rail has atop surface which include plurality of linearly aligned holes along itslength, two horizontally extending side walls and two end walls whichdefine an inner cavity. Within the cavity is a series of interconnected,linearly aligned, upwardly protruding support members operativelyassociated with an apparatus for urging the support members through theopenings in the top surface of the rail to create a workpiece supportsurface above the rail. Hence, the support members are adjustable from afirst position above the top of the rail to a second position below thetop of the rail.

The support members rest atop a plank which rests on a skid slidablypositioned within the cavity. The plank is free to move vertically, butnot laterally. The plank has a series of slots formed in its lengthwhich correspond to a series of ramps positioned on the skid below theplank. The skid can move laterally. The relationship between the slotsand the ramps is such that by moving the skid in one lateral direction,one side of each of the slots is forced to ride up the incline of itscorresponding ramp, thereby raising the plank carrying the supportmembers to a position where the support elements protrude through theopenings in the top wall of the rail. When the skid is moved in theother lateral direction, the slots slide down the incline on the ramps,thereby lowering the plank and the support members. The tops of theramps are flat to allow the plank to rest atop the ramps and maintainthe support members in the first position above the rail. A handle,attached to the skid through a slot formed in one of the sides of therail, enables the user to impart the desired lateral movement to skid soas to raise or lower the support members.

Hence, the present invention provides a simple to control mechanism thatallows the user to selectively and quickly raise or lower the workpieceatop the sawhorse rail depending on the operation being performed onthat workpiece.

In addition, the rail in the present invention is designed to resideatop both fixed and collapsible legs or supports. The present inventionis readily adaptable to numerous shapes and sizes, and may beconstructed of many materials, such as wood, plastics and metals.

Other objects and additional features of the present invention will bein part apparent and in part pointed out hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the preferred embodiment of the novelsawhorse rail atop a sawhorse, shown in phantom, with the supportmembers in the lowered position within the body of the rail;

FIG. 2 is a perspective view of the embodiment of FIG. 1, with thesupport members in the fully raised position above the surface of therail;

FIG. 3 is an exploded view of the embodiment of FIG. 1;

FIG. 4 is a perspective view of one of the ramp elements of the sawhorserail;

FIG. 5 is a cross-sectional side elevation of the sawhorse rail, showingthe support members in the lowered position within the body of the rail;

FIG. 6 is a cross-sectional side elevation of the preferred embodiment,showing the support pegs in the fully raised position above the body ofthe rail;

FIG. 7 is a perspective view of the sawhorse rail attached to a pair offolding leg braces with a folding shelf below the rail, showing the legsfully open and the shelf locked flat;

FIG. 8 is a perspective view of the embodiment of FIG. 7, showing thelegs closed together and the shelf folded up between the legs; and

FIG. 9 is perspective view of one end of the folding shelf of themodified embodiment, showing the tabs and grooves at the center hinge.

Corresponding reference characters indicate corresponding partsthroughout the several views of the drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The preferred embodiment of the novel sawhorse rail is indicatedgenerally at 10 (FIGS. 1 and 2). The rail 10 may be used independentlyor it may be fastened to a set of sawhorse legs, as depicted in ghostimages in FIGS. 1 and 2, by any of a number of common andwell-understood means, such as bolts or screws between the rail 10 andthe legs, a clamping device, or glues such as epoxy. Alternatively, therail 10 may be simply placed atop a set of legs without firm attachment.

The sawhorse rail 10 includes a top wall 11, a first vertical side wall12, a second vertical side wall 14, a base 16, and a first vertical endwall 18 and second vertical end wall 20. When fully assembled, the bodyof the rail 10 is hollow, i.e. having an inner cavity defined by therecited walls and base. Near the center of the lower edge of the sidewall 12 is a horizontal notch 22.

Referring to FIG. 3, it can be seen that a track 23 is formed in, andruns the full horizontal length of the centerline of the top surface ofthe base 16. A horizontal notch 25 is formed in the side of the track 23that aligns in registry with the notch 22 in the side wall 12 to form ahandle opening along the side of the rail 10. A slidable skid 24 restsin the track 23. The skid 24 is slightly thinner than the width of thetrack 23, and somewhat shorter than the base 16. This allows the skid 24to slide freely within the track 23, between the end walls 18 and 20within the body of the rail 10 as will be explained below.

A series of linearly aligned, equally shaped ramps 26 are fixedlyattached to the top surface of the skid 24. Each of the ramps 26 (FIG.4) has a rectangular base 28 with three vertical walls 30, 32 and 34, anincline 36, and a short, flat, horizontal platform 38 at the top of theincline 36. The ramps 26 are equidistant apart from one another alongthe skid 24, and oriented such that each incline 36 ascends from theskid 24 in the same angular direction. A handle 40 is also fixedlyattached to the skid 24. The handle 40 is positioned along one side ofthe skid 24 such that the handle corresponds with and extendshorizontally through the opening formed by the notches 22 and 25 in theside of the rail.

A plank 42 rests atop the skid 24 inside the body of the rail 10. Theplank 42 is generally the same width, but is longer than the skid 24,such that the ends of the plank 42 nearly abut the inner surfaces of theend walls 18 and 20. The plank 42 has a series of linearly alignedrectangular openings 44 between each end. The number of the openings 44is the same as the number of the ramps 26 on the skid below. Each of theopenings 44 locates directly over one of the ramps 26 when the skid 24is close to or abuts the inner surface of the first end wall 18. Becausethe openings 44 are slightly longer and wider than the base 28 of theramps 26, the openings 44 can readily slide up and down over the ramps26.

A set of equally dimensioned upwardly extending support members, shownas pegs 46, are attached in a along the top of the plank 42. The pegs 46are positioned on the plank 42 to align with corresponding circularholes 48 in the top wall 11 of the rail 10. The holes 48 are slightlylarger in diameter than the pegs 46, such that the pegs 46 may movefreely up and down within the holes 48. It will be appreciated that pegs46 could have a rectangular or other cross section if desired, providedthe holes 48 have a complimentary shape. The height of the pegs 46 isslightly less than the distance from the top of the plank 42 to the topof the holes 48 (FIG. 5).

It is evident to one skilled in the art that when the skid 24 is restingat a first position adjacent the first end wall 18, the ramps 26 willfit fully inside the openings 44 in the plank 42. In this alignment, theplank 42 rests atop the skid 24, and the tops of the pegs 46 are lowerthan the tops of the holes 48. When the handle 40 is pushed toward thesecond end wall 20 (FIG. 6), the skid 24 and the ramps 26 travel in thesame direction toward end wall 20. Because the plank 42 is constrainedfrom lateral movement by the end walls 18 and 20, the ramps 26 areforced to slide under the edges of the openings 44 adjacent the bottomof the inclines 36. The force of the ramps 26 wedging under the edges ofthe openings 44 causes the plank 42 to ascend in a level fashion upalong the inclines 36. This, in turn, raises the pegs 46 on the plank 42through the holes 48. As the handle 40 moves further toward the secondend 20, the pegs 46 will continue to ascend through the holes 48 untilthe inclines 36 are entirely under the plank 42. At this point, theplank 42 will then slide across, rest upon, the platforms 38 atop theramps 26, and the pegs 46 will be fully extended above the surface oftop wall 11 of the rail 10. Two or more of the tops of the pegs 46, incooperation with one another, thereby form an elevated support surfacefor workpieces atop the sawhorse.

When the handle 40 is then actuated in the opposite direction, i.e.toward the first end wall 18 (FIG. 7), the skid 24 and the ramps 26travel in the same direction. As before, the plank 42 is stillconstrained from lateral travel by the ends 18 and 20. Now, however, theramps 26 slide along the platforms 38 under the plank 42 until theplatforms 38 are fully within the openings 44. Thereafter, the plank 42begins to descend as the ramps 26 slide back into the openings 44 alongthe inclines 36. This causes the pegs 46 to simultaneously descendthrough the holes 48. As the handle 40 moves further toward the firstend 18, the pegs 46 will continue to descend through the holes 48 untilthe ramps 26 are entirely within the openings 44 and the plank 42 isagain resting atop the skid 24. At this point, the tops of the pegs 46will be below the top of the holes 48 in top wall 11 of the rail 10.

FIGS. 7 and 8 show another embodiment of the present invention in whicha rail 10′, having a top wall 11′, side walls 12′ and 14′, a base 16′,and end walls 18′ and 20′, is mounted on a collapsible sawhorse S′. Inthis embodiment, two equally shaped leg braces 50 are pivotally attachedalong their tops to the side walls 12′ and 14′ of the rail 10′ by a pairof hinges 52. Each of the leg braces 50 is a flat plate having agenerally rectangular top portion 51 with two broad, flat-bottomed legs53 at the opposite end. The bases 54 of both legs 53 on each leg brace50 are parallel to one another. The leg braces 50 can fold in towardsone another along the side walls 12′ and 14′, as in FIG. 8. The hinges52 are both horizontal, parallel to one another, and located at the sameheight above the bottom of the rail 10′. In order to accommodate thehinge 52, notches 22′ and 25′, are in a higher position along side 12′than the notches 22 and 25 along the side 12 in the preferredembodiment. This requires that handle 40′ attach along the skid 24′ anddescend vertically within the body of the rail 10′ to attach to skid24′.

A folding shelf 55 is positioned between the leg braces 50. The shelf 55is formed from two generally rectangular plates 56 that are pivotallyconnected to one another along the center of the shelf 55 by a hinge 58.A series of interlocking tabs 60 extend from the centermost edges of theplates 56 above the hinge 58. The tabs 60 are shaped to lay flat in aseries of complementary shaped grooves 62 (FIG. 9) on the opposed plate56 when the plates are coplaner and the shelf 54 is flat. (FIG. 7). Thetabs 60 therefore form a stop that prevents upward rotation of theplates 56 about the hinge 58 beyond the point where the plates 56 arecoplaner.

Each long side 63 of the shelf 55 is parallel to the hinge 58 andpivotally attaches to each of the four legs 53 by hinges 64. The hinges64 on each leg brace 50 are coaxial with one another and runhorizontally along the inner sides of the legs 53. On each of the legbraces, the hinges 64 are both equidistant from the base of the legs 53.

Hence, when the leg braces 50 are closed together, as in FIG. 8, theshelf 55 is folded in half and extends vertically above the hinges 64between the legs 53. When the leg braces 50 are pivotally opened awayfrom one another about the hinges 52, the two plates 56 begin to rotateabout the hinges 64 at their outer ends and simultaneously rotate aboutthe hinge 58 at their center, causing the center of the shelf 55 tolower. As the center of the shelf 55 moves downward, the tabs 60 alsomove from a nearly vertical orientation toward a horizontal orientation.The leg braces 50 can continue to rotate open until the shelf 55 isfully horizontal. At that point, the tabs 60 lock into the grooves 62,the top of the shelf 55 is flat, and the structure of the shelf 55,being fully extended, prevents the leg braces 50 from opening further.The shelf 55 has a width such that when the leg braces 50 are fullyopened, the distance between the legs 53 are far enough apart to provideample stability while maintaining a suitable working height for thecrown 11 of the sawhorse.

The present invention, therefore, enables the user to easily,controllably, and rapidly raise a workpiece supported by the rail 10above the top of the top surface rail 10. This enables the user toperform various operations on the workpiece without repositioning. Bysimply sliding the handle 40 in one direction, the workpiece can beraised above the rail 10 on the pegs 46. By simply returning the handle40 to its original position, the workpiece will be lowered back onto thetop wall 11 of the rail 10. The rail 10 can be located on virtually anysolid work surface, such as the on the ground, a tabletop, a bench, achair, etc., or the rail 10 can be configured atop a sawhorse. Thus, thepresent invention greatly reduces the risk of damage to the work surfaceor the sawhorse, and the tools, and virtually eliminates the need toreposition workpieces on the rail 10 to avoid contact between the rail10, the work surface or the sawhorse, and various tools duringoperation. Additionally, embodiments of the present invention may alsoinclude collapsible or telescoping legs that enable ready storage andtransport of the rail 10, and rapid set-up to a sawhorse.

Other variations on the basic apparatus are also available. For example,the base 16 could be formed without the track 23 such that the skid 24simply rests atop the base 16 within the body of the rail 10. The handle40 could be located at any position along either of the sides 12 or 14of the rail 10, or extend out from either of the ends 18 or 20, wherethe handle would be pushed and pulled. The number of the ramps 26 andthe openings 44 can vary from one to many. Similarly, the number of thepegs 46, and the holes 48 can be varied from one to many. Bearing,bushings and other friction reducing devices can be placed at variouslocations throughout the apparatus, such as between the skid 24 and thebase 16, between the skid 24 and the plank 42, and in the openings 44and 48, to enhance the functioning of the apparatus without deviatingfrom the scope of the invention. Further, the sides of the openings 44nearest the bottom of each incline 36 can be rounded, angled, orotherwise shaped to further enhance the sliding capability of the ramps26 within the openings 44. Similarly, bearings or bushings can beincorporated along the same side of the openings 44.

In addition, the dimensions of the apparatus can vary significantly,including, but not limited to, widening or thinning the crown 11, theramps 26, the skid 24, the plank 42 and the base 16. The ramps 26 can beexchanged with one or more other components that will enable the plank42, and the pegs 46 or other similar supports, to rise within the rail10 by moving the handle 40. The angle of the inclines 36 for the ramps26 can be varied to virtually any angle less than 90 degrees, and can beoriented toward either the end 18 or the end 20. The inclines 36 on theramps 26 can be concave or convex. The shape of the pegs 46 and theirassociated holes 48 can be varied to virtually any cross-sectionalshape. A locking mechanism or device can be employed to lock the skid 24into one or more desired positions. Finally, each of the components ofthe invention can be manufactured from a variety of materials,including, but not limited to, plastics, metals and woods, so long asthe apparatus maintains the same functionality and the necessarystructural integrity.

Springs or other devices may be incorporated in the apparatus to applyforces against certain components. For example, springs can be placedaround one or more of the pegs 46 to apply a force against the top ofthe plank 42 that will hold the plank 42 in the downward-most positionwithin the rail 10 when the additional elevation is not needed.Anti-skid material can be added to components of the apparatus, such asatop the pegs 46. Two or more smaller hinges can be substituted for anyof the long hinges 52, 58 and 64, so long as sufficient structuralintegrity is maintained.

As various changes could be made in the above constructions withoutdeparting from the scope of the invention, it is intended that allmatter contained in the above description or shown in the accompanyingdrawings shall be interpreted as illustrative and not in a limitingsense.

What is claimed is:
 1. An apparatus for elevating a workpiece above awork surface comprising: a horizontal rail having an upper plane; atleast one support member within the rail, said at least one supportmember being moveable from a position below the upper plane of thehorizontal rail to a position above the upper plane of the horizontal tosupport the workpiece above the upper plane of the horizontal rail; anda ramping apparatus below said at least one support member for movingsaid at least one support member from the position below the upper planeof the horizontal rail to the position above the upper plane of thehorizontal rail, said ramping apparatus having a handle thereon foractuating a lateral movement of said ramping apparatus.
 2. The apparatusof claim 1 further comprising a plurality of linearly aligned supportmembers.
 3. The apparatus of claim 1 wherein said ramping apparatusfurther comprises a skid assembly positioned under the at least onesupport member wherein movement of said skid assembly by said handle ina first direction moves the at least one support member above the upperplane of the rail and movement of said skid assembly in a seconddirection by said handle moves said at least one support member belowthe upper plane of the rail.
 4. The apparatus of claim 3 wherein saidskid assembly further comprises at least one ramp element thereon toeffect movement of the at least one support member in response tomovement of the skid assembly in the first or second direction.
 5. Anapparatus for elevating a workpiece above the top of a sawhorsecomprising: a horizontal rail for use on the sawhorse, said rail havinga top wall, opposed horizontally extending side walls and opposed endwalls, said recited walls defining a chamber; a plurality ofinterconnected, upwardly projecting support member within the horizontalrail; a skid positioned below said interconnected, upwardly projectingsupport members, said skid having a handle and ramp elements on an uppersurface, said ramp elements disposed to urge said plurality ofinterconnected, upwardly projecting support members to a position abovethe top wall of the horizontal rail upon lateral movement of said skidby said handle to a first position within the chamber to support theworkpiece above the sawhorse.
 6. The apparatus in claim 5 wherein saidramps on said skid are disposed to permit said plurality ofinterconnected, upwardly extending support members from the positionabove the top wall of the horizontal rail to a position below the topwall of the horizontal rail upon movement of the skid by said handle toa second position.
 7. The apparatus in claim 6, further comprising aresistance member, the resistance member oriented to directly resist themovement of the skid.
 8. The apparatus in claim 6, further comprising alocking mechanism, the locking mechanism being capable of engagement toprevent movement of the skid.
 9. The apparatus in claim 5, wherein thetop wall of the horizontal rail has a plurality of linearly alignedopenings formed therein.
 10. An apparatus for elevating a workpieceabove the top of a sawhorse comprising: a horizontal rail for use on thesawhorse, said rail having a top wall, opposed horizontally extendingside walls and opposed end walls, said recited walls defining a chamber;a plurality of interconnected, upwardly projecting support memberswithin the horizontal rail; a skid, having a handle thereon, positionedbelow said interconnected, upwardly projecting support members, saidskid having a series of linearly aligned upwardly orientated rampelements on an upper surface positioned to urge said plurality ofinterconnected, upwardly projecting support members to, and support in,a position above the top wall of the horizontal rail to support theworkpiece above the sawhorse upon movement on said skid by said handleto a first position within the chamber.
 11. The apparatus in claim 10further comprising a vertically movable but laterally constrained plankatop the skid, the plank supporting the plurality of interconnected,upwardly extending support elements.
 12. The apparatus of claim 11wherein said plank has a plurality of slots formed therein in, said oneeach of said slots oriented to accommodate one each of the ramps. 13.The apparatus in claim 12 further comprising a track positioned belowthe skid and formed to receive the skid, wherein the skid is free tomove horizontally along the length of the track but is constrained fromany other horizontal movement.
 14. The apparatus in claim 10, furthercomprising a platform formed on the top of the ramps, wherein the plankmay rest atop the ramps.
 15. A sawhorse capable of elevating a workpieceabove the top of the sawhorse comprising: a horizontal rail at the topof the sawhorse, said rail having an top wall with a plurality ofopenings formed therein, as opposed side walls and opposed end walls,said recited walls defining a body with a chamber formed therein; ahorizontally move skid within the chamber, said skid comprising a seriesof upwardly oriented ramps on an upper surface of the skid, each ramphaving a platform formed on top such that the plank may rest levellyatop the ramps; a vertically movable but laterally constrained plankatop the skid having a plurality of slots formed therein, wherein oneeach of slot of said plurality of slots is oriented to correspond withone each of said series of ramps; a plurality of support memberspositioned atop the plank such that one each of said plurality ofsupport members is aligned with one each of said plurality of openingsformed along the top wall of the rail, a track positioned below the skidand formed to receive the skid such that the skid is free to movehorizontally along the length of the track but constrained from anyother horizontal movement; a handle attached to the skid through a slotformed in one of the said long sides of the body; and wherein lateralmovement of the skid to a the first position causes one edge of each ofthe slots to translate along a ramp corresponding to that edge, therebysimultaneously moving the plank and the plurality of support member invertical direction whereby the plurality of support members protrude theplurality of openings in the top wall forming a workpiece supportsurface above the top wall of the rail.
 16. The sawhorse of claim 15further comprising a leg assembly at each end of the horizontal railwherein each leg of said pair of depending legs is rotatably attachedalong its top portion to opposing long sides of the rail.
 17. Thesawhorse of claim 16, further comprising a horizontal shelf rotatablyconnected at each end to one of said depending legs, said shelf having ahinged center with interlocking tabs that rises when the legs arerotated toward one another, but that locks when in a horizontal positionand thereat forms a flat upper surface.